Impact-absorbing headgear liner and skull cap

ABSTRACT

A protective impact-absorbing headgear liner for use with various types of helmets and protective gear or clothing. The lining material has unique impact absorbing properties to additionally protect a wearer from impact related injuries. The headgear liner has a band and crown which are variously shaped and positioned to received impact-absorbing pads. The position of the pockets depends on the helmet style. In one example the liner is a stretchable material. Impact absorbing pads as described herein may be used in a variety of clothing and protective gear to protect from impact injury. Examples are football shoulder ads, thigh pads, bicycle helmets and the like. The liner may also be an expanded foam. A preferred pad material is a gel containing a thermoplastic elastomer.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional PatentApplication No. 61/520,778 filed Jun. 14, 2011, and U.S. ProvisionalPatent Application No. 61/530,275 filed Nov. 1, 2011 the contents ofwhich are hereby incorporated by reference.

TECHNICAL FIELD

This description relates generally to protective, impact-absorbingheadgear/helmet liner and more specifically, to a protective liner to beworn under various types of helmets for additional impact protection.

BACKGROUND

Impacts resulting in head injuries are a common occurrence in manyactivities such as football, hockey, cycling and other activities. Theproblem is particularly critical in sports such as football as played atall levels. A recent report indicated that even at the NFL level, manyplayers wear helmets that received low ratings for reducing the risk ofconcussion.

The term “concussion” is derived from the Latin term “concutere” andoften results from head-on, helmet-to-helmet impacts. Some research alsoshows that head trauma is often caused by impact or blows to the side ofthe face as well as a result of direct head-on collisions.

Concussions may be associated or result in a variety of symptoms afteran injury which vary widely in nature and seriousness with headachebeing the most common. Dizziness, vomiting, lack of motor coordinationmay follow. In addition to these, physical symptoms, cognitive symptomsinclude confusion and disorientation. Concussion-causing impacts maydetrimentally affect various parts of the brain including the midbrain,the fornix, temporal and frontal lobes.

Individuals such as athletes subjected to repeated concussions mayexhibit a decline in physical and mental performance over time. Thecumulative effects may increase the chance of early development ofAlzheimer's, brain swelling, neurological problems and even result inmortality.

As a result of medical concerns in the field of sports, variousapproaches have been undertaken in head protection which attempt tolessen or absorb the effect and severity of impacts and blows to thehead, although, as pointed out, many athletes continue to wear helmetsthat do not perform well.

While these various approaches have, to some extent, improved helmetperformance and reduced impact, there nevertheless exists a need forfurther improvements in the field of headgear safety, and in particularto utilizing materials that more effectively absorb impact that arelight weight, compact and reusable.

SUMMARY

The following presents a simplified summary of the disclosure in orderto provide a basic understanding to the reader. This summary is not anextensive overview of the disclosure and it does not identifykey/critical elements of the invention or delineate the scope of theinvention. Its sole purpose is to present some concepts disclosed hereinin a simplified form as a prelude to the more detailed description thatis presented later.

The present examples provide a separate, impact-absorbing helmet linerto be worn beneath various types of helmets. In one example, the lineris a skull-type cap of a stretchable, breathable material which will fitsnugly on the head of the wearer. A circumferential band, preferablyhaving an elasticized section, encircles the wearer's head, extendingaround the temporal, frontal and occipital areas. The circumferentialband defines a plurality of pockets which may be variously sized andpositioned to received impact-absorbing pads. The placement of thepockets may be selected in accordance with the type of helmet andactivity, as the areas most susceptible to impact blows will vary withthe activity. Generally the pockets are spaced circumferentially aroundthe band and contain an impact-absorbing material which may be permanentinserts or in the form of removable and replaceable pads.

The liner also has a integral crown portion attached to thecircumferential band that extends across the top of the wearer's head.The crown portion of the liner also defines at least one of a pluralityof selectively positioned pockets which receive either permanent orremovable pads. The crown pocket typically extend across the top of thehead from the forehead area to the back of the neck. The pockets aretypically constructed so that no fasteners are needed. But if desiredpockets having closures such as loop-and-hook fasteners or the like maybe constructed.

The impact or alternatively energy absorbing gel pads are preferably agel material such as disclosed in U.S. Pat. Nos. 7,041,719 entitled“Shock Absorbing Compound” and U.S. Pat. No. 6,896,065. This particularimpact absorbing gel material may be composed of an epoxidized vegetableoil, a thermoplastic polymer and a prepolymer. The energy absorbingcompound is a polymeric compound which exhibits good energy-attenuatingproperties and is capable of absorbing repeat shocks without structuraldamage. The pads may be of varying thickness, depending on theirplacement and type of activity with which they are to be used. The useof this particular material tends to reduce the thickness of the padsneeded, as its energy absorbing characteristics per unit volume tend tooutperform those of other commonly utilized materials.

In an alternate embodiment, the liner may be an expanded foam backedwith the impact absorbing gel material. Pockets are also provided forreceiving impact-absorbing pads to absorb impacts to the headtransmitted through a helmet or other equivalent heads gear. The padsare preferably removable. Many of the attendant features will be morereadily appreciated as the same becomes better understood by referenceto the following detailed description considered in connection with theaccompanying drawings.

DESCRIPTION OF THE DRAWINGS

The present description will be better understood from the followingdetailed description read in light of the accompanying drawings,wherein:

FIG. 1 is a perspective view of an example of a helmet liner accordingto the present invention including impact or energy absorbing gel pads;

FIG. 2 is a side view showing the helmet liner of FIG. 1 worn by aplayer for under helmet protection;

FIG. 3 is a bottom view of the helmet liner showing an illustrativepocket opening for accepting a gel pad;

FIG. 4 shows a front and top view of the helmet liner.

FIG. 5 is a perspective view showing the position of the gel insertswithout the supporting fabric of the cap, and as they would be held inplace by the fabric.

FIG. 6 shows a wearer wearing a football helmet showing the liner of thepresent invention in dotted lines.

Like reference numerals are used to designate like parts in theaccompanying drawings.

DETAILED DESCRIPTION

The detailed description provided below in connection with the appendeddrawings is intended as a description of the present examples and is notintended to represent the only forms in which the present example may beconstructed or utilized. The description sets forth the functions of theexample and the sequence of steps for constructing and operating theexample. However, the same or equivalent functions and sequences may beaccomplished by different examples.

The present examples uniquely provide a gel helmet liner that may beconfigured in any variety of configurations in order to utilize gelmaterial as described herein, either alone or in combination with othermaterials to absorb shock applied to the helmet. The impact absorbinggel is soft enough to conform its shape to a certain extent that isuseful in improving the fit of various items. The impact absorbing gelis particularly useful in that when used in helmets it has the abilityto fill voids between the wearer and the helmet, making for a betterfit, and better transfer of impact to the gel where the force of impactmay be absorbed.

FIG. 1 is a perspective view of an example of a skull cap or helmetliner 10. The skullcap 10 includes a support liner 109 for a pluralityof unique impact absorbing gel pads 102, 104, 106, 108. Such a liner mayadvantageously be worn under a hard helmet to distribute the force ofimpacts received in play or other activities. This liner shape alsolends itself for use with certain styles and types of helmets which donot enclose as much of the wearer's head as do full face football,hockey goalie and similar helmets. In addition to football helmets,representative applications would be bicycle helmets, skiing protectiveheadgear, skateboarding helmets and climbing helmets. The skull cap maybe worn as shown, but may be reversed if desired. The helmet liner 10includes a plurality of impact or energy absorbing gel pads such asthose shown in this view 102, 104, 106,108 which may be disposed invarious pockets 101, 103, 105, 107 disposed at advantageous positions ina supporting cap 109.

The supporting cap structure 109 that supports the pads shown 102, 104,106, 108, and holds them in place, shown here is assembled from severalcomponents including a circumferential head-encircling band 12, and anintegrally formed crown 14, and an edging 16. Alternatively each ofthese components may include sub-components as desired, for exampleadditional pieces of material that may be used to form pockets 101, 103,105, 107, as desired. These components may be made of the same ordiffering materials, fabric, mesh or the like as desired. In particularmaterial that may be stretched, or that includes elastic mayadvantageously employed so that the cap stays in position on a player'shead. The band 12 and crown 14 are both of a lightweight, breathablematerial such as a micro fiber, Spandex, etc. that is typically able tostretch in two directions. The various components may usually beassembled by sewing. Elasticized thread or non-elasticized thread may beused to sew the carious components as desired. Other equivalent methodsof joining the component pieces may also be employed if desired.

In addition to the use of mesh material or netting perforations or vents(not shown) may also be provided at selected areas in the crown and bandfor ventilation and to allow heat to escape from the wearer's head.Perforations may also be provided in the crown. In addition pads havingapertures disposed therein may be used to increase comfort.

The supporting cap structure 109 may be provided in various sizes foruse by both adult and younger athletes, although stretchability willadapt for use by several head sizes. The band 12 has a series ofgenerally rectangular pockets 101, 103, 105 in which shock absorbing gelpads 102, 104, 106 may be disposed extending about the band. The pocketspockets 101, 103, 105, each have a slot or opening (not shown) throughwhich impact-absorbing pads may be inserted and removed. The slots mayinclude optional fasteners if desired.

The selected pads 102, 104, 106, 108 will generally conform to the shapeof the associated pocket 101, 103, 105, 107 and are shown as removable,generally rectangular inserts. Generally elongated, rectangular padconfigurations for insertion in the band may be provided however otheralternative shaped pads may be provided, including additional pads fitin the crown 14 in similarly configured pockets in this particularexample. The shapes described above could be selected for use infootball helmets or the like. The pads 102, 104, 106, 108 may be a foamor similar material but are preferably gel pads as described below.

While various types of impact absorbing materials may be used for padssuch as foam and the like. However, a unique impact absorbing gelmaterial has been found to be very effective in absorbing anddistributing impact. The gel pads of this material may be cut formed orotherwise shaped from stock having a variety of thicknesses including 2mm, 8 mm, 12 mm and 14 mm exemplary thicknesses. The material is alsoadvantageously compact given its impact absorbing qualities, typicallywith pads of about 25% of the thickness of other padding materials,equivalent or better impact absorbing characteristics are obtained. Apreferred gel material is a non-toxic material with high energyabsorbing capacity. One such preferred material is an epoxidizedvegetable oil containing a thermoplastic elastomer along with aprepolymer.

The impact or energy absorbing gel which is further described in U.S.Pat. No. 7,041,719 by Kriesel and Goodenough, for “Shock AbsorbingCompound” filed Sep. 26, 2003; U.S. Pat. No 6,896,065 by Kriesel andLyle for “Hoofed Animal Pad” filed Jul. 3, 2003; and U.S. Pat. No.6,588,511 by Kriesel and Lyle for “Hoofed Animal Pad” filed Mar. 7,2002, the disclosures of which is hereby incorporated by reference.

The gel material can be provided with stabilizers to resist fungus andbacteria, an important characteristic in athletic wear which is subjectto heat, moisture and perspiration. In addition the gel material may beperforated with apertures of any convenient shape or shapes. Perforationallows for air circulation and improved cooling so that perspiration mayevaporate more readily, increasing comfort to the wearer.

The gel material may also be combined with other substances, either in amixture, layered structure or other suitable combination to form a pad.Typical structures might include gel disposed on a layer or layers overa layer or layers of styrene foam, an air bladder, or a mixture of gelmaterial with air disposed throughout the gel.

FIG. 2 is a side view showing the helmet liner of FIG. 1 worn by aplayer for under helmet protection prior to a helmet being put on. Thematerial is stretchable so the liner will snugly and firmly encircle atleast the top portion of the wearer's head. When worn, the band 12extends around the frontal, temporal an occipital region of the head andthe crown.

In alternative example one or more elastic sections positionedintermediate the impact-absorbing pad receiving pockets 202 may beprovided to enhance stretchability, fit and adaptability of the liner tovarious head sizes. The crown may also be provided with a plurality ofpockets to receive impact-absorbing pads, either permanent orreplaceable to protect the head as needed in other desired applications.

FIG. 3 is a bottom view of the helmet liner showing an illustrativepocket opening 302, disposed in a pocket 107 for accepting a gel pad108. Each pocket disposed in the helmet liner 10 may have similaropenings for removal or insertion of the pads. As seen a diagonal 304flap is formed that tends to overlap the abutting fabric similarly cut,so that when a pad 108 is inserted the gel material is not exposed, asit might prove uncomfortable to the wearer.

Gel pads 108 may be easily disposed in a pocket enclosure of this typeas they are flexible. In this example a flap 304 of material overlaps anopposing piece of material 306 to form an opening 302 in which a pad108, may easily be inserted or removed without the need for hardware,which might be unsafe or uncomfortable for a wearer. The material isflexible allowing the pad to be positioned. In use the material istaught on the wearer's head closing the cavity with the taught material,and keeping the pad 40 in place. Providing removable pads is useful asthe pads may be removed and the skull cap may be washed separately.

The opening may optionally include cooperable loop-and-hook fasteners toallow the convenient and selective insertion and removal of pads 108,although a slot or aperture on the interior of the crown may besufficient to retain the pads in most cases.

FIG. 4 shows a front and top view of the helmet liner. In this view allof the pad locations of the five gel pads 102, 104, 106, 108, 402 ofthis example are shown.

FIG. 5 is a perspective view showing the position of the gel inserts102, 104, 106, 108, 402 without the supporting fabric of the cap, and asthey would be held in place by the fabric. As can be see the inserts arequite thin, and flexible, so that they may be cut from a planar sheetbut still remain flexible enough to conform to the shape of the wearer'shead.

In addition one or more pieces 102, 106 may be used to adjust the linersize. Impact absorbing gel pieces may act as a self-adjusting gel tailfitting piece 102 and forehead fitting piece 106, here shown as arectangles or alternatively as squares. In alternative examples thefitting piece may be other shapes such as round oval, having roundedcorners and the like. The fitting piece or pieces allows size adjustmentby selecting a suitably sized fitting piece allowing a single sized sideor crown pieces to be used. Alternatively fewer side and crown piecevariations in size might be needed. The fitting piece additionallyprovides additional protection over leaving a gap to allow for sizing.

FIG. 6 shows a player 601 wearing a football helmet 602 with the liner10 between the player's head 603 and his conventional football helmet602 showing the liner 10 of the present invention in dotted lines. Asshown the addition of the impact-absorbing liner or skull cap 10provides a shock absorbing under layer to typical athletic head gear602. In order to accommodate the impact-absorbing liner or skull cap aconventional helmet of a size can be selected. In an alternate examplethe impact-absorbing liner or skull cap may be used in conjunction witha simple hard shell helmet, without padding, or having any paddingremoved. In a further alternative example the impact-absorbing liner orskull cap may be provided with hardware such as hook and loop tape, orthe like to prevent its shifting within the helmet.

There are various shapes and configurations for the impact-absorbing gelpad(s). The various embodiments of the liner of the present inventioncan be adapted to the requirements of the individual and the activity inwhich the wearer participates.

A liner may be constructed that includes mandible extensions whichextend downwardly towards the chin, and may include a chin strap to helpsecure the cap in place. Alternatively the mandible extensions may beomitted, with a chin strap still provided. The mandible extensions 350have openings 375 for better sound transmission. The openings may alsoreceive impact-absorbing inserts 340 insertable in or around the earopenings.

And in further alternative examples the impact-absorbing liner or skullcap may be disposed as an integral part of the helmet. In such aconfigurations either the liner its self may be made removable forwashing, the pads alone may be removable for washing, or both may beremovable for washing.

In alternative examples tubes or strips of the previously described gelmay be disposed in a skull cap. This example in particular allowsroughly pencil sized plastic (or its equivalent) of gel to be insertedin pockets or cavities disposed in a skull cap for shock absorption. Thestrips or tubes may radiate from the crown, may form concentric circles,a spiral or the like. Weight and ventilation tend to be improved inthese examples.

In yet another alternative examples of the skullcap a “T” shaped gel pador a circular gel pad in cooperation with rectangular pads in insertedinto a support liner having suitably formed pockets. These examplesadvantageously utilize the sewn envelopes previously described.

In yet another alternative example of the skull cap size adjustment canbe achieved without elastic, or in addition to it. Fabric tails may becoupled to the skull cap by sewing or other suitable bonding processes.The tails may be tied together to adjust the fit of the skull cap. Tyingwould typically be done in the back, but tying in the front or otherconvenient locations would be possible. Also the skull cap could befabricated as a scarf with pockets which is tied up and worn so that theposition of the impact absorbing gel pads provides the desiredprotection under the headgear.

Finally the impact absorbing gel pads utilized and described herein maybe used in athletic gear and protective gear as either additionalprotection disposed between the conventional protective gear and thewearer, or incorporated into the design of such protective gear. Theapplication of the gel material to athletic equipment and the like forimpact reduction is wide ranging. The impact absorbing gel pads may alsobe sewn into articles of clothing, such as hip pads, knee pads and thelike. Also, the gel may be incorporated into mouth guards, for exampleby providing an insert into the tray of a mouthpiece so that the teethclose upon the impact absorbing gel protecting them from damage.

It will be obvious to those skilled in the art to make various changes,alterations and modifications to the invention described herein. To theextent such changes, alterations and modifications do not depart fromthe spirit and scope of the appended claims, they are intended to beencompassed therein.

Those skilled in the art will realize that the process sequencesdescribed above may be equivalently performed in any order to achieve adesired result. Also, sub-processes may typically be omitted as desiredwithout taking away from the overall functionality of the processesdescribed above.

1. An under helmet liner comprising: (a) a circular head-encircling bandhaving a crown; (b) said band and crown each defining at least onepocket; and (c) an impact-absorbing gel pad in said pocket.
 2. The linerof claim 1 wherein the pads are removable from the pockets.
 3. The linerof claim 2 wherein the pockets are formed by overlapping pieces offabric.
 4. The liner of claim 1 wherein the pads are an impact-absorbinggel.
 5. The liner of claim 4 wherein the gel is a thermoplastic resin.6. The liner of claim 1 wherein the band and crown are an elasticized,stretchable material.
 7. The liner of claim 1 wherein the impactabsorbing gel pad includes an expanded foam disposed on the impactabsorbing gel pad.
 8. The liner of claim 1 wherein the liner has a tailpiece formed from impact absorbing gel to adjust a size of the liner. 9.The liner of claim 1 wherein the location of the pockets are selected toprovide impact-resistance in areas based on the type of helmet andactivity.
 10. The liner of claim 1 wherein the liner includes vents. 11.The liner of claim 1 wherein the liner is moisture-absorbent.
 12. Aprotective gear system comprising: an article of protective gear todesigned to protect a wearer from an impact related injury; and athermoplastic elastomer material disposed between the article ofprotective gear and a wearer of the protective gear to further absorb animpacting force whereby the wearer is further protected.